Air filter arrangement; assembly; and, methods

Abstract

An air filter media construction or arrangement is disclosed. The air filter media construction or arrangement includes media comprising opposite inlet and outlet flow faces, with a perimeter housing seal. Also described are serviceable filter cartridges and air cleaners including the filter cartridges. Methods of assembly and use are also provided.

What is claimed: 
     
       1. An air filter cartridge comprising:
 (a) a filter media pack having a first flow face and a second, opposite, flow face, wherein:
 (i) the filter media pack includes filter media arranged between the first flow face and the second, opposite, flow face; 
 (ii) the filter media pack having a rectangular cross-sectional shape, in a direction perpendicular to a central flow axis extending between the first flow face and the second, opposite, flow face; and 
 (iii) the filter media pack comprising four sides extending between the first flow face and the second, opposite, flow face, wherein the four sides include a first pair of first and second opposite sides, and a second pair of first and second opposite sides; 
 
 (b) end pieces molded in place and covering the first pair of first and second opposite sides of the filter media pack, wherein the end pieces seal the first pair of first and second sides of the filter media pack; 
 (c) a frame piece having a rectangular cross-section, in a direction perpendicular to the central flow axis, and extending around the four sides of the filter media pack, wherein:
 (i) the frame piece includes an extension extending in a direction away from a remainder of the frame piece; and 
 (ii) the frame piece includes a plurality of apertures therethrough, wherein the plurality of apertures are located over the second pair of first and second opposite sides of the filter media pack; and 
 
 (d) a seal member molded to the extension of the frame piece and constructed to form an axial pinch seal when the air filter cartridge is installed in an air cleaner housing. 
 
     
     
       2. An air filter cartridge according to  claim 1  wherein:
 (a) the end pieces each extend over at least a portion of each of the first flow face, the second flow face, and the second pair of first and second opposite sides. 
 
     
     
       3. An air filter cartridge according to  claim 2  wherein:
 (a) the end pieces are spaced apart from each other. 
 
     
     
       4. An air filter cartridge according to  claim 1  wherein:
 (a) the end pieces comprise an indent arrangement provided as a recess from an outer surface of the end pieces. 
 
     
     
       5. An air filter cartridge according to  claim 4  wherein:
 (a) the indent arrangement is formed during molding of each of the end pieces by supporting the filter media pack so that the filter media pack is located above a mold. 
 
     
     
       6. An air filter cartridge according to  claim 1  wherein:
 (a) the seal member includes a portion located around the filter media. 
 
     
     
       7. An air filter cartridge according to  claim 1  wherein:
 (a) the seal member includes opposite sides arranged to be pinched to form the axial pinch seal, and wherein the extension extends between the opposite sides of the seal member. 
 
     
     
       8. An air filter cartridge according to  claim 1  wherein:
 (a) the frame piece comprises a single, integral, molded frame piece. 
 
     
     
       9. An air filter cartridge according to  claim 1  wherein:
 (a) the frame piece does not completely cover the second pair of first and second opposite sides of the filter media pack. 
 
     
     
       10. An air filter cartridge according to  claim 1  further comprising:
 (a) a grid system extending over an outlet flow face of the media pack. 
 
     
     
       11. An air filter cartridge according to  claim 1  wherein:
 (a) the filter media pack comprises alternating fluted media and facing media. 
 
     
     
       12. An air filter cartridge according to  claim 11  wherein:
 (a) the alternating fluted media and facing media are secured to each other. 
 
     
     
       13. An air filter cartridge according to  claim 12  wherein:
 (a) the alternating fluted media and facing media secured to each other comprises a stack of alternating strips of a fluted media sheet secured to a facing media sheet. 
 
     
     
       14. An air filter cartridge according to  claim 11  wherein:
 (a) the filter media pack comprising alternating fluted media and facing media comprises flutes extending in a direction along the central flow axis. 
 
     
     
       15. An air filter cartridge according to  claim 14  wherein:
 (a) at least a portion of the flutes do not extend a complete distance between the first flow face and the second flow face. 
 
     
     
       16. An air filter cartridge according to  claim 15  wherein:
 (a) at least a portion of the flutes are closed prior to one of the first flow face and the second flow face. 
 
     
     
       17. An air filter cartridge according to  claim 16  wherein:
 (a) the flutes closed prior to one of the first flow face and the second flow face are closed by folding the flutes closed. 
 
     
     
       18. An air filter cartridge according to  claim 11  wherein:
 (a) the alternating fluted media and facing media comprises straight flutes. 
 
     
     
       19. An air filter cartridge according to  claim 11  wherein:
 (a) the alternating fluted media and facing media comprises non-straight flutes. 
 
     
     
       20. An air filter cartridge comprising:
 (a) a filter media pack having a first flow face and a second, opposite, flow face, wherein:
 (i) the filter media pack includes filter media arranged between the first flow face and the second, opposite, flow face; 
 (ii) the filter media pack having a rectangular cross-sectional shape, in a direction perpendicular to a central flow axis extending between the first flow face and the second, opposite, flow face; and 
 (iii) the filter media pack comprising four sides extending between the first flow face and the second, opposite, flow face, wherein the four sides include a first pair of first and second opposite sides, and a second pair of first and second opposite sides; 
 
 (b) end pieces molded in place and covering the first pair of first and second opposite sides of the filter media pack, wherein:
 (i) the end pieces seal the first pair of first and second sides of the filter media pack; 
 (ii) the end pieces comprise an indent arrangement provided as a recess from an outer surface of the end pieces extending toward the filter media pack; 
 
 (c) a frame piece having a rectangular cross-section, in a direction perpendicular to the central flow axis, and extending around the four sides of the filter media pack, wherein:
 (i) the frame piece includes an extension extending in a direction away from a remainder of the frame piece; and 
 (ii) the frame piece includes a plurality of apertures therethrough, wherein the plurality of apertures are located over the second pair of first and second opposite sides of the filter media pack; and 
 
 (d) a seal member molded to the extension of the frame piece and constructed to form an axial pinch seal when the air filter cartridge is installed in an air cleaner housing.